Asphaltene Decontamination via Flocculation
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Solution Overview
Problem
Current methods for upgrading heavy oil and bitumen are limited by the difficulty in removing asphaltenic contaminants, which leads to high viscosity and poor processability, resulting in incomplete separation and high capital-intensive processing requirements.
Innovation Solution
A process using non-aromatic light hydrocarbons as a decontaminating agent at a low ratio to precipitate asphaltenes, facilitating their separation by flocculation and subsequent extraction, thereby reducing viscosity and enabling effective separation of oil and water phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional solvent deasphalting is used to remove asphaltenes, then some asphaltene separation is achieved, but the process requires high solvent to oil ratio (40:1 by volume) and multiple theoretical stages, resulting in high device complexity and capital intensity
Solution Approach 1:
The invention changes the fundamental parameter of the separation mechanism from solvent-based dissolution to flocculation-based aggregation. By controlling conditions to promote flocculation of asphaltene particles into larger aggregates, the process achieves effective separation at much lower solvent ratios (comparable to conventional deasphalting rather than 40:1) and with simpler equipment requirements, eliminating the need for multiple theoretical stages while maintaining separation purity
Solution Approach 2:
The invention extracts the harmful asphaltene contaminants from the heavy oil feedstock through flocculation and separation. The process selectively removes asphaltenes and other contaminants in a single operation rather than requiring multiple sequential separation stages, thereby reducing device complexity and capital intensity while maintaining effective purification
2Manufacturing precision
If high solvent to oil ratio is used in solvent deasphalting, then more complete asphaltene precipitation is achieved, but the process becomes more capital intensive and requires larger equipment volumes
Solution Approach 1:
The invention changes the separation mechanism from solvent dissolution to flocculation aggregation. This parameter change allows the process to achieve complete asphaltene precipitation and removal with minimal solvent volume, comparable to conventional deasphalting ratios rather than requiring 40:1 solvent to oil ratios, thereby significantly reducing equipment volumes and capital requirements
3Temperature
If conventional deasphalting processes are used, then some viscosity reduction is achieved, but the resultant asphaltic materials remain too viscous to be transportable without high heating temperatures, leading to fouling and plugging
Solution Approach 1:
The invention extracts and removes the harmful asphaltene contaminants that cause high viscosity and transport problems. By effectively separating asphaltenes from the bulk oil, the process produces a decontaminated oil product with significantly improved flow characteristics that can be transported at lower temperatures without causing fouling or plugging issues
4Manufacturing precision
If multiple conventional processing stages are used to remove contaminants, then some purification is achieved, but the process requires high capital investment and is difficult to achieve clean separation
Solution Approach 1:
The invention merges multiple separation functions into a single flocculation-based process stage. By combining asphaltene precipitation, oil-water separation, and contaminant removal into one integrated operation rather than requiring multiple sequential stages, the process achieves high purification quality while significantly reducing device complexity and capital investment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves substantial asphaltene precipitation and separation, improving the quality and yield of petroleum products by removing 50% to 99% of asphaltenes, reducing fouling, and enhancing the transportability and processability of heavy oil.
Implementation Method 1
facilitating their separation by flocculation and subsequent extraction
Implementation Method 2
treating the asphaltene/water phase from step (c) with additional decontaminating agent to extract residual oils
Data Source
AI summary
A process and apparatus to remove asphaltenic contaminants from bitumen, heavy oil or residue to produce lower viscosity petroleum products and high purity asphaltenes.